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KAVAN Cumul 100 - Instruction manual
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===== Wing centre section ===== * Cut out all the CNC milled ribs using a sharp modeller’s knife or jigsaw, check them with the plan and mark the numbers on them with a soft pencil or marker. Sand as necessary to fit all spars easily. * Assemble the main spar shear webbing. Epoxy the '''W30''' wing joiner bays to the '''W29''' balsa parts. Enclose the bays; epoxy the '''W31''' plywood plates (front side of the shear webbing) and '''W32''' (rear side). Prevent the epoxy from hardening inside the bays. Put the parts together with the carbon joiner inserted, then immediately remove the joiner (do not forget cleaning the joiner using a paper tissue and rubbing alcohol before the glue sets). '''(Det. B, Fig. 3)''' * Bind the joiner bays with the provided Kevlar® thread and soak with medium CA or epoxy. Epoxy together both two shear webbing halves reinforcing the joint with the plywood joiners '''W27''' (short one, front side) and '''W28''' (long one, rear side). '''(Det. B, Fig. 3+4+5)''' * Epoxy together the wing central ribs '''W1''' and '''W2'''. Insert 3 mm beech dowels into the holes in order to obtain correct match.<br>{{Note|'''Note:''' Make a left and right pair of ribs.|type=info}} * Epoxy the plywood wing bolt plates '''W15''' and '''W18''' between the '''W1'''/'''W2''' ribs. Glue the balsa blocks '''W16''' and '''W17''' onto them (trim the '''W17''' first to match the outline of the '''W1''' ribs). Sand the W16 flush with the edge of '''W2''' ribs. '''(Fig. 6)''' * Glue the '''W26''' flap servo trays between the '''W5''' ribs.<br>{{Note|'''Note:''' Make a left and right pair of assemblies.|type=info}} * You can use medium cyano for gluing most of the wing centre section parts. In that case you are supposed to put together most of the wing without glue at first. Once checked for the correct alignment, the cyano is applies to the joints from the outside. Or you can use white glue. In that case the wing is assembled step by step pinned down on the building plan protected by a thin clear plastic film. Start with pinning down the '''W9''' bottom main spar. The '''W11''', '''W12''', '''W14''' and '''W38''' parts are to be glued after the wing is removed from the building board. * '''Assembling the wing using cyano:''' Insert all ribs and riblets into the respective notches, slide on the '''W13'''/'''W19''' trailing edge. Cyano the '''W6''' ribs to the shear webbing using the 7 deg dihedral jig (the '''W7''' outer ribs are to be glued later - after the wing centre section has been paired with the wing panels). * Insert, but not glue, the '''W11''' auxiliary spar (5 mm balsa) and the '''W12''' flap leading edge (7 mm balsa). Align the top edge of these parts flush with the top edge of the ribs (you will trim the protruding part at the bottom later, once glued in place). * Cyano the '''W25''' flap horn blocks in place. * Double check the correct position of all ribs and spars. Lay the wing on the building plan. Once satisfied, apply cyano to all joints.<br>{{Note|'''Note:''' Be sure not to glue the '''W11''' and '''W12''' parts to each other, just to the ribs.|type=info}} * Insert and cyano the '''W10''' rear spar (6×3 mm pine stick). * Pin down the wing centre section to your building board. Butt joint the '''W9''' main spar (10×2 mm pine) to the edge of the '''W39''' top D-box sheeting (1.5 mm balsa). Apply white glue to the top of the ribs, riblets and the main spar shear webbing. Insert the '''W9''' main spar into the notches in all ribs and pin it down. Then step by step pin down the '''W39''' balsa sheeting to the ribs. * Once the glue has cured, remove the wing from your building board. Glue the '''W14''' support spar in place as well as the '''W9''' bottom main spar. Use white glue to secure the '''W38''' bottom D-box sheeting in place. '''(Fig. 7)''' * Sand the front edge of the '''W39''' and '''W38''' balsa sheeting flush with the front edge of the ribs and glue the '''W8''' leading edge in place. * Glue the '''W24''' bottom cover plates of the flap servo bays between the '''W5''' ribs. Glue the '''W33''' flap root ribs in place. * Sheet the space between '''W2''' ribs from the bottom and top with '''W20a''', '''W20b''' (with the '''W40''' connector reinforcement plate glued on top), '''W21''', '''W22''' and '''W23'''. '''(Det. C)''' * Sand the sheeting flush with the edges of '''W2''' ribs. Drill the hole for the front wing bolt through the '''W39''' top sheeting. Taper the top edges of the wing bolt holes to match the supplied countersunk screws. Soak the tapered area with thin cyano to reinforce it. * Glue the '''W47''' gussets in place. * Fine sand the entire wing centre section, pay attention to the leading edge, sand the W6 ribs flush. Trial fit the flap servos. Prepare the aileron and flap extension cables. To allow threading the cables after the wing has been covered, you should put a thread through the holes in ribs secured by strips of sticky tape. Or you can glue 6 mm plastic tubes (not included in the kit). See the dotted lines on the building plan. There is a pair of the MPX8 8-pin connectors supplied in the kit suitable for the cable connection of aileron and flap servos and your receiver. The male part (with pins) is to be secured by screws into the fuselage, the female part into the wing. '''(Fig. 11+21)''' * Solder the extension cables with (+) and (-) pins shared, the remaining pins are for the servo signal leads. You can use regular servo connectors between the wing centre section and outer panels, but the sturdier MR30 connectors ([https://kavanrc.com/item/mr30-connector-1pair-145913 KAV36.131] - not supplied in the kit) are more suitable for the task. If you are going to use them, install the male part (with pins) of the connector into the wing centre section. It is probably for the best installing all the cables before the wing is covered. Do not forget double-check the correct polarity and connection first! The connectors are to be cyanoed to the wing after the covering. * Use a fine razor saw to cut the root part of flaps through the '''W13'''/'''W19''' trailing edges and between '''W33''' and '''W2''' ribs. Cut through the ribs between the '''W11''' auxiliary spar and '''W12''' flap leading edge with a sharp modeller’s knife or razor saw and remove the flaps. Bevel the leading edge in 27 degrees angle, allowing the up deflection of the flaps (flaps are hinged on the bottom side of the wing). '''(Fig. 8)''' * Trial fit the carbon wing joiners into the respective bays. There should be a tight fit, no play. If there was a significant play, put some epoxy to the appropriate area of the joiner and sand as necessary once the glue hardens. Trial fit the '''W7''' liteply outer ribs - do not glue yet.
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